Patent Application
20060108970
The present invention generally relates to the field of fuel cells and particularly, to a family of power tools implementing a common fuel cell system for standardizing the power requirements for the tools within the family. The fuel cell system is integrated with the family of power tools for providing power to those tools. In addition, individual power tools within the family may be semi-customized to accommodate the fuel cell system.
Carpenters regularly utilize certain power tools when working at a jobsite. For example, a power tool such as a portable generator may be utilized for providing power to other tools, such as saws and drills, when a standard electrical power source outlet is not available. Also, a portable compressor may be utilized for providing power to a pneumatic fastener, such as a nailer. Portable generators typically are run by gas-powered engines. The problem with such generators is that they are often noisy and also emit fumes associated with gas combustion, thus making them impractical to use in areas where ventilation is poor. Portable compressors typically are run by a motor, thus requiring access to a standard electrical power source outlet. When an outlet is not nearby, a carpenter utilizing such a compressor may be forced to utilize one or more extension cords to connect the compressor to a remotely located outlet. As a result, extension cords clutter the work area and can be in the way of those trying to move about the jobsite.
Therefore, it would be advantageous to have a family of power tools, such as portable generators or portable compressors, which could be powered by a common power system for maximum increase in flexibility and convenience.
Accordingly, a first aspect of the present invention is directed to a system wherein each member of a family of power tools individually includes a common fuel cell system for providing power to each tool within the family.
A second aspect of the present invention is directed to a battery charger including a fuel cell system in accordance with an exemplary embodiment of the present invention. The battery charger is configured for charging removable batteries for power tools.
A third aspect of the present invention is directed to a workstation including a fuel cell system in accordance with an exemplary embodiment of the present invention. The workstation further includes one or more work lights, for illuminating a workspace and a battery charger docking station, for charging removable batteries for power tools.
A fourth aspect of the present invention is directed to a portable compressor including a fuel cell system in accordance with an exemplary embodiment of the present invention. The portable compressor is configured for powering tools.
A fifth aspect of the present invention is directed to a portable generator including a fuel cell system in accordance with an exemplary embodiment of the present invention. The portable generator is configured for powering corded devices.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Referring generally to
The uniform fuel cartridge is configured for interchangeable use among the tools within the family. In additional embodiments, the fuel cell system allows for tools within the family to be configured with multiple fuel cell units based on power demand. In an exemplary embodiment, a tool within the family, such as a portable generator, includes a plurality of stackable fuel cell units. Each stackable fuel cell unit is configured for removably receiving one or more uniform fuel cartridges. Multiple stackable fuel cell units may be utilized as necessary based on power demand. The present invention therefore provides a unified system of providing power to a family of power tools and also, provides a scheme for allowing the family of tools to provide power to tools of various voltages.
Referring to
The battery charger 100 further includes a docking station 104, which is at least partially contained by the housing 102. The docking station 104 is configured with one or more corresponding physical connectors for physically coupling a removable battery 110, such as for utilization with a family of cordless tool batteries employing common physical connections. For example, the docking station 104 may be configured with rails for slidably coupling a removable battery 110. The docking station 104 is further configured with one or more corresponding terminals for electrically coupling a removable battery 110, such as for utilization with a family of cordless tool batteries employing common electrical schemes. For instance, the docking station 104 may be configured with electrical contacts, such as blades, posts and the like for electrically coupling a removable battery 110.
The battery charger 100 further includes a fuel cell system. The fuel cell system includes at least one fuel cell unit 106, such as a hydrogen/oxygen (PEM) fuel cell unit, and at least one corresponding uniform fuel cartridge 108, such as a methanol fuel cartridge. In a present embodiment, the fuel cell unit 106 is at least partially contained by the docking station 104. The fuel cell unit 106 is also configured with a port for removably receiving and coupling with, such as by a post connection, the uniform fuel cartridge 108. In an exemplary embodiment, the port of the fuel cell unit 106 is configured to fully accept the cartridge 108. In additional embodiments, the port is configured to partially accept the cartridge 108. Embodiments in which the cartridge 108 is fully accepted provide the advantages of reducing the profile of the battery charger 100 and better protecting the cartridge 108. In a preferred embodiment, the cartridge 108 is generally rectangular-shaped and is notched or tapered to accommodate manual removal of the cartridge 108 from the port.
The cartridge 108, upon introduction via the port, is physically coupled with the fuel cell unit 106 in such a manner as to allow for the transport of fuel, such as pressurized hydrogen, from the fuel cartridge 108 to the fuel cell unit 106. Upon disconnection of the cartridge 108 from the fuel cell unit 106, the fuel cartridge 108 is configured to prevent the flow of fuel from the cartridge 108. In an exemplary embodiment, the cartridge 108 includes one or more connectors, such as spring-loaded valves, and the fuel cell unit 106 is configured with one or more corresponding receptors, which removably receive and couple with the spring-loaded valves of the cartridge 108. Upon insertion of the cartridge 108 into the port, the spring-loaded valves of the cartridge 108 are received by the receptors of the fuel cell unit 106, which allows for the transport of fuel from the cartridge 108 to the fuel cell unit 106. The fuel cell unit 106 converts hydrogen and oxygen received from the uniform fuel cartridge 108 into water, thereby producing electrical energy. Further, the fuel cell unit 106, being electrically coupled with circuitry of the battery charger 100, provides this electrical energy via the circuitry for charging a battery 110 coupled with the docking station 104 of the battery charger 100. Upon disconnection from the receptors, the spring-loaded valves are further configured to prevent the flow of fuel from the cartridge 108. In a preferred embodiment, the cartridge 108 is disposable. In an alternative embodiment, the cartridge 108 may be refueled.
In additional embodiments, the port includes a mechanism for ejecting the uniform fuel cartridge 108. In one embodiment, the ejection mechanism is a push-button mechanism that activates levers configured within the port. The levers proceed to push against the cartridge 108, thereby disconnecting the connectors of the cartridge 108 from the receptors of the fuel cell unit 106 and ejecting the cartridge 108 from the port. In other embodiments, the ejection mechanism is a spring-loaded mechanism and the like.
In a preferred embodiment, the fuel cell system is configured so that a single uniform fuel cartridge 108 and fuel cell unit 106 allow the battery charger 100 to recharge a battery 110 within the run-down time of a tool utilizing a substantially similar battery. For example, if the rundown time for a 19.2-volt battery for a cordless drill is 2 hours, the fuel cell system preferably is configured so that the battery charger 100 is able to recharge the battery in less than 2 hours. This way, a user of the cordless drill 112 can continue working using a spare battery while a first battery is recharging and the first battery will be recharged and ready for use before the spare battery runs down. Those of skill in the art will appreciate that run-down time may include time during which a tool is not operating, such as time between drilling operations and the like. In additional embodiments, the fuel cell system is configured so that a single uniform fuel cartridge 108 is able to recharge a battery multiple times before the cartridge has to be replaced or refueled.
In a further embodiment, the battery charger 100 includes one or more indicators which provide information to a user regarding the various components of the battery charger. For example, a visual (i.e.—blinking light, LED graphical indicator) or an audible indicator provides an indication as to when a battery 110 has begun and/or commenced charging, when a uniform fuel cartridge 108 needs replaced and the like.
In additional embodiments, the battery charger 100 includes a device for connection to a standard electrical power source outlet. In further embodiments, a battery charger 100 configured to accept a standard electrical power source connection also includes a power conditioner, such as a signal/line conditioner, a double line conversion conditioner and the like. The power conditioner assists in providing an uninterrupted flow of electricity from the standard electrical power source to the battery charger 100.
In further embodiments, the housing 102 includes a plurality of recesses contoured for receiving/storing items such as a power tool 112, a uniform fuel cartridge 108, a removable battery 110 not undergoing recharging, a power cord and the like. In the illustrated embodiment, the housing 102 is contoured with a plurality of recesses disposed within its upper portion for allowing clearance for the housing 102 to be established in a closed position while a removable battery 110 is being charged. In additional embodiments, the housing 102 may include one or more vents for dissipating heat from within the housing 102.
In exemplary embodiments, the electronics of the battery charger 100 are configured, upon connection of the battery charger 100 to a standard power source outlet, to automatically operate the battery charger 100 exclusively from the standard power source rather than the fuel cell system. This feature conserves fuel cell system resources and also allows for refueling or replacement of the cartridge 108. In embodiments in which the battery charger 100 is being operated from a standard power source, the electronics of the battery charger 100 are able to detect the presence of a coupled battery 110 and allocate an appropriate amount of current from the standard power source to the docking station 104 for charging the coupled battery. In an exemplary embodiment, upon fully charging the coupled battery 110, the battery charger 100 may provide a trickle charge for keeping the battery 110 fully charged and conserving electricity.
Referring to
The workstation 200 also includes one or more work lights 206 for illuminating a workspace where the workstation 200 may be employed. In an exemplary embodiment, each work light 206 includes a plurality of fluorescent bulbs contained within an enclosure. The work lights 206 are removably and rotatably attached to the handle member 204. The handle member 204 is configured with a plurality of corresponding turning knobs 216, the knobs 216 being mechanically and rotatably coupled to the work lights 206, thereby allowing a user to manually rotate the work lights 206.
The workstation 200 further includes a docking station 208, which is at least partially contained by and disposed within an upper surface of the supporting base 202. The docking station 208 is configured with one or more corresponding physical connectors, such as generally opposed rails, and one or more corresponding electrical contacts for physically and electrically coupling a removable battery 214, such as for utilization with a family of cordless tool batteries employing common physical connections and electrical schemes. Further, the workstation 200 includes circuitry for directing electricity to the work lights 206 and the docking station 208.
The workstation 200 further includes a fuel cell system, the fuel cell system having at least one fuel cell unit 210 and at least one corresponding uniform fuel cartridge 212. The fuel cell unit 210 is at least partially contained within the supporting base 202 and is electrically coupled with the circuitry of the workstation 200 in such a manner that the fuel cell unit 210 may charge a removable battery 214 and illuminate the worklights 206. The fuel cell unit 210 is configured with a port for removably receiving the uniform fuel cartridge 212. The uniform fuel cartridge 212 is removably coupled to the fuel cell unit 210 via the port. In an embodiment, the cartridge 212 is fully accepted by the port. In a further embodiment, the cartridge 212 is partially accepted by the port. In additional embodiments, the port includes an ejection mechanism for ejecting the uniform fuel cartridge 212.
The cartridge 212, upon introduction via the port, is physically coupled with the fuel cell unit 210 in such a manner as to allow for the transport of fuel from the cartridge 212 to the fuel cell unit 210. Upon disconnection of the cartridge 212 from the fuel cell unit 210, the fuel cartridge 212 is configured to prevent the flow of fuel from the cartridge 212. The fuel cell unit 210 converts hydrogen and oxygen received from the uniform fuel cartridge 212 into water, thereby producing electrical energy for charging a battery 214 coupled with the docking station 208 of the battery charger 200 and for illuminating the worklights 206. The workstation 200 may also include a power (ON/OFF) switch for the worklights 206.
In a preferred embodiment, the fuel cell system is configured so that a single uniform fuel cartridge 212 and fuel cell unit 210 are able to provide power to both the work lights 206 and the battery charger docking station 208 of the workstation 200. Preferably, the fuel cell system is configured to recharge a battery 214 within the run-down time for a tool utilizing a substantially similar battery, while also providing power for illuminating the work lights. In further embodiments, the fuel cell system is also configured so that a single uniform fuel cartridge 212 is able to recharge a battery 214 multiple times before the cartridge has to be replaced or refueled.
In a further embodiment, the workstation 200 includes one or more indicators for providing information to a user regarding the various components of the workstation such as the status of a fuel cartridge 212 or a charging battery 214. In additional embodiments, the workstation 200 includes a device for connection to a standard electrical power source outlet. In embodiments where a workstation 200 is configured to accept a standard electrical power source connection, the workstation may also include a power conditioner for providing an uninterrupted flow of electricity to the workstation 200.
In current embodiments, electronics of the workstation 200 are configured, upon connection of the workstation to a standard power source outlet, to automatically operate the workstation exclusively or partially from the standard power source, thereby conserving fuel cell system resources. In embodiments in which the workstation 200 is being operated from a standard power source, the electronics of the workstation 200 are able to detect the presence of a coupled battery 214 and allocate an appropriate amount of current from the standard power source to the docking station 208 for charging the coupled battery. In an exemplary embodiment, upon fully charging the coupled battery 214, the workstation 200 may provide a trickle charge for keeping the battery 214 fully charged and conserving electricity.
In further embodiments, the worklights 206 are configured to run off of a removable battery 214 coupled with the docking station 208 when the fuel cell system is not producing electrical energy.
Referring to
The compressor 300 further includes a fuel cell system, the fuel cell system having at least one fuel cell unit 316 and at least one corresponding uniform fuel cartridge 318. The fuel cell unit 316 is at least partially contained within the housing 302. In an exemplary embodiment, the fuel cell unit 316 is electrically coupled via circuitry of the compressor 300 with at least one internal battery, which is at least partially contained by the housing of the compressor 300. The internal battery stores electrical energy provided by the fuel cell system. The internal battery is electrically coupled with the motor 306 of the compressor 300 and provides the stored energy to the motor 306, thereby allowing the motor 306 to meet peak power demands of the compressor 300. The internal battery is configured for a family of tools employing a common voltage scheme, such as for power tools. The fuel cell unit 316 is configured with a port for removably receiving the uniform fuel cartridge 318. The uniform fuel cartridge 318 is removably coupled with the fuel cell unit 316 via the port. In an embodiment, the cartridge 318 is fully accepted by the port. In a further embodiment, the cartridge 318 is partially accepted by the port. The cartridge 318, upon introduction via the port, is physically coupled with the fuel cell unit 316 in such a manner as to allow for the transport of fuel from the cartridge 318 to the fuel cell unit 316. Upon disconnection of the cartridge 318 from the fuel cell unit 316, the fuel cartridge 318 is configured to prevent the flow of fuel from the cartridge 318. The fuel cell unit 316 converts hydrogen and oxygen received from the uniform fuel cartridge 318 into water, thereby producing electrical energy for charging the internal battery, thereby allowing the internal battery to power the compressor 300. In additional embodiments, the port includes an ejection mechanism for ejecting the uniform fuel cartridge 318.
Preferably, the fuel cell system of the present invention is configured so that a single uniform fuel cartridge 318 and fuel cell unit 316 provide enough electrical energy to the internal battery to allow the compressor 300 to power low demand tools, such as a nailer. When powering multiple or higher demand tools or appliances, further embodiments of the compressor 300 may be configured with various combinations of multiple fuel cell units 316 and multiple internal batteries to meet peak power demands.
In additional embodiments, the compressor 300 includes a device for connection to a standard electrical power source outlet. In further embodiments, a compressor 300 configured to accept a standard electrical power source connection also includes a conditioner for providing an uninterrupted flow of electricity to the compressor 300.
In further embodiments, electronics contained within the compressor 300 are configured, upon connection of the compressor to a standard power source outlet, to automatically operate the compressor exclusively or partially from the standard power source to conserve battery resources. In alternative embodiments, the compressor 300 includes one or more indicators, which provide information to a user regarding the various components of the compressor. In additional embodiments the compressor 300 includes one or more inverters 314, if for example the portable compressor includes an AC motor.
Referring to
The generator 400 further includes a fuel cell system, the fuel cell system having at least one stackable fuel cell unit 410 and at least one corresponding uniform fuel cartridge 412. The stackable fuel cell unit 410 is removably configured between the housing 404 and the supporting base 402. In an exemplary embodiment, locking knobs 408, configured with the housing 404, are manually adjusted to manipulate a locking mechanism, which secures the stackable fuel cell unit 410 between the housing 404 and the supporting base 402. For example, the locking mechanism may be a series of slide locks, through rods, quick coupling locks, twist locks, bayonet locks, and the like. Further, the stackable fuel cell system is electrically coupled with circuitry of the generator 400 for providing electrical power for the generator 400. In further embodiments, the stackable fuel cell unit 410 is electrically coupled with at least one internal battery, which is at least partially contained by the supporting base 402 or housing 404 of the generator 400. The internal battery stores electrical energy provided by the stackable fuel cell unit 410 and may use its stored electrical energy to provide power for the generator 400. The internal battery is configured for a family of tools employing a common voltage scheme, such as for power tools. The stackable fuel cell unit 410 is configured with one or more ports for removably receiving a uniform fuel cartridge 412. The uniform fuel cartridge 412 is removably coupled with the stackable fuel cell unit 410 via the port. In an embodiment, the cartridge 412 is fully accepted by the port. In a further embodiment, the cartridge 412 is partially accepted by the port. The cartridge 412, upon introduction via the port, is physically coupled with the stackable fuel cell unit 410 in such a manner as to allow for the transport of fuel from the cartridge 412 to the fuel cell unit 410. Upon disconnection of the cartridge 412 from the fuel cell unit 410, the fuel cartridge 412 is configured to prevent the flow of fuel from the cartridge 412. In additional embodiments, the port includes a mechanism for ejecting the uniform fuel cartridge 412.
Preferably, the fuel cell system is configured so that a single uniform fuel cartridge 412 and stackable fuel cell unit 410 allow the generator 400 to power low demand tools or appliances, such as a radio. When powering multiple or higher demand tools or appliances, exemplary embodiments of the generator 400 are configured with multiple stackable fuel cell units 410 and/or one or more internal batteries in order to meet power demands. In further embodiments, one or more inverters are included for standardizing the current. In additional embodiments, the electronics of the generator 400 are configured to control the power draw from the stackable fuel cell units 410. For example, the electronics are configured to equalize the power draw from individual stackable fuel cell units 410 and the like. The generator 400 may be further configured to allow a user to manually determine the power draw from each stackable fuel cell unit. In further embodiments, the housing 404 is configured with an inverter, if for example, the generator 400 is being used to power an AC motor of a coupled device.
Individual stackable fuel cell units 410 are configured to provide a uniform current when coupled with other stackable fuel cell units 410. Preferably, each stackable fuel cell unit 410 is a discrete fuel cell stack configured to provide a standard voltage and current, rather than the stackable fuel cell units 410 forming a single fuel cell stack for the entire generator 400. Configuring the generator 400 so as to allow for semi-customization allows the user to minimize the size of the generator, permits rapid stackable fuel cell unit changing, easy removal of defective units, and the like. In a further embodiment, the generator 400 includes one or more indicators, which provide information to a user regarding the various components of the generator.
It is believed that the present invention and many of its attendant advantages will be understood by the forgoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages, the form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
The present application is a continuation-in-part (CIP) application and claims priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 10/868,344 entitled: Integrated Fuel Cell System filed Jun. 14, 2004, which in turn claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/477,906 entitled: Fuel Cell Assembly filed Jun. 11, 2003, both of which are hereby incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60477906 | Jun 2003 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10868344 | Jun 2004 | US |
| Child | 11109493 | Apr 2005 | US |
